US20140125270A1 - Reclaiming Energy Stored In Rechargeable Batteries For Charging Other Batteries - Google Patents
Reclaiming Energy Stored In Rechargeable Batteries For Charging Other Batteries Download PDFInfo
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- US20140125270A1 US20140125270A1 US13/672,483 US201213672483A US2014125270A1 US 20140125270 A1 US20140125270 A1 US 20140125270A1 US 201213672483 A US201213672483 A US 201213672483A US 2014125270 A1 US2014125270 A1 US 2014125270A1
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- batteries
- battery
- energy
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- H02J7/0054—
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
- H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
- H01M10/482—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for several batteries or cells simultaneously or sequentially
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
- H01M10/4285—Testing apparatus
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
- H01M10/44—Methods for charging or discharging
- H01M10/446—Initial charging measures
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
Definitions
- Certain types of a battery such as a large lithium polymer or a large lithium ion phosphate battery used in an electric automotive vehicle application, may have a manufacturing process which includes charging the battery and at a later time discharging the battery. This cycling may be done in part or in full more than one time. This charging, storage, and discharging the battery may be done to test the battery, to store energy, to release energy, to help in the forming of the battery, or for other reasons.
- charging the battery in its manufacturing process is accomplished using an electronic battery charger which converts power from the AC power mains to a DC form readily useable by the battery.
- the battery is traditionally charged alone or with one or more batteries in series, parallel, or in a series/parallel combination.
- the battery discharge in its manufacturing process is typically accomplished by connecting the battery to a resistive load.
- the battery is traditionally discharged by itself or with one or more batteries in series, parallel, or in a series/parallel combination.
- the electronic battery charger typically converts power from the available AC mains into the DC form required by the battery. This AC power consumed incurs a cost to the manufacturing facility.
- a lithium polymer or lithium ion phosphate battery for automotive electric vehicle applications is charged and discharged along with other batteries in series and/or in parallel during the manufacturing process.
- a failure of a battery is often not detected until after the charging or discharging cycle is complete and the battery is connected to a test station. Where the failed battery had been charged in series with other batteries, the entire string of batteries being charged often needed to repeat the charging cycle again.
- the energy for charging a lithium polymer or a lithium ion phosphate battery during the manufacturing process of said battery will be partly or fully provided by other batteries which are being discharged during their manufacturing process, the process of charging one battery and concurrently discharging one or more different batteries speeds-up testing through-put when compared to sequential manufacturing, energy from the AC mains that has been used to charge a battery may be partly recycled and used to charge one or more other batteries, the energy consumption from the AC mains to cool the manufacturing facility may be reduced, and each battery may be monitored during charging/discharging and replaced in real time if a problem is detected.
- FIG. 1 is a circuit diagram of the first embodiment
- FIG. 2 is a system flowchart outlining an example machine using the first embodiment
- FIG. 3 is a circuit diagram of alternative embodiment
- FIG. 4 is a system flowchart outlining an example machine using the alternative embodiment
- FIG. 1 shows the circuit diagram of a battery charging, discharging, and testing machine for use in battery manufacturing and which may be used specifically with the type of lithium ion phosphate batteries that power electric vehicles.
- an initially charged battery 101 a which has a negative terminal 101 a ⁇ and a positive terminal 101 a +, is on the bottom and an initially charged battery 101 b , which has a negative terminal 101 b ⁇ and a positive terminal 101 b +, is on the top of this series connected pair.
- the positive terminal of the top battery 101 b + is connected through a switch 108 to an ammeter 106 which is represented in FIG.
- the switch 108 can be set to one of two possible positions by a computer control 105 .
- the switch 108 could be placed in an open configuration where it disconnects the initially charged battery 101 b from the ammeter 106 .
- the computer control 105 In addition to controlling the switch 108 , the computer control 105 also controls the variable resistance load 104 .
- a computer inputs/outputs 107 connects to and performs measurements (including voltage readings) on all battery terminals as well as the ammeter 106 .
- An additional initially charged battery 109 a and an additional initially discharged or uncharged battery 109 b are present but are not connected to the circuit.
- a bar code scanner 110 for identifying each battery is also attached to the computer inputs/outputs 107 , and a robot 111 is connected to the computer control 105 .
- the computer control 105 and the computer inputs/outputs 107 are some of the interfaces to a computer 102 .
- the machine in FIG. 1 follows the machine flowchart of FIG. 2 .
- the switch 108 is set to open circuit.
- the initially charged battery 101 a on the bottom and the initially charged battery 101 b at the top of the series batteries are installed along with the initially uncharged or discharged battery 103 into the machine's circuit via the robot 111 which concurrently uses the scanner 110 to read the serial numbers of the batteries as they are being installed.
- This serial number data enters the computer inputs/outputs 107 and is recorded in a file on the computer 102 .
- battery 103 In order to continue in their manufacture process, battery 103 must be charged and batteries 101 a and 101 b must be discharged. These three batteries are assembled into the circuit of FIG. 1 as shown.
- the computer inputs/outputs 107 measures and/or performs tests on these three batteries individually. This data is recorded in the file with the respective battery's individual serial number.
- the computer 102 analyzes the collected data from the battery measurements and determines if the batteries are functioning properly. If not, the failed battery is removed by the robot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on the computer 102 , and an appropriate replacement battery is loaded into the circuit. If the batteries are properly functioning, the computer 102 determines the appropriate resistance—based on measured battery voltages and an algorithm—and sets the variable resistance load 104 . It closes the switch 108 and discharging of the initially charged batteries 101 a and 101 b into the initially uncharged or discharged battery 103 begins.
- the computer inputs/outputs 107 continue to monitor the batteries and the computer 102 determines if they are properly functioning. If a problem is detected, the switch 108 is opened and the failed battery is removed by the robot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on the computer 102 , and an appropriate replacement battery is loaded into the circuit.
- the computer 102 next determines if either of the initially charged batteries 101 a and 101 b is fully discharged. If one is, the switch 108 is opened. The computer 102 next determines if the discharged battery delivered the required stored energy. If so, the battery passes, is removed by the robot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on the computer 102 , and an appropriate replacement battery 109 a is loaded into the circuit. If the discharged battery did not deliver the required stored energy, the battery fails and is removed by the robot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on the computer 102 , and an appropriate replacement battery 109 a is loaded into the circuit.
- the computer 102 next determines if the initially uncharged or discharged battery 103 is fully charged. If it is, the switch 108 is opened. The computer 102 next determines if the charged battery 103 received the required stored energy. If so, the battery 103 passes, is removed by the robot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on the computer 102 , and an appropriate replacement battery 109 b is loaded into the circuit. If the charged battery 103 did not receive the required stored energy, the battery 103 fails and is removed by the robot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on the computer 102 , and an appropriate replacement battery 109 b is loaded into the circuit.
- this alternative embodiment utilizes a DC power supply 112 whose positive output is connected to the previously open side of the switch 108 and whose negative output is connected to the positive terminal 101 a + of the battery 101 a to be discharged. Additionally, the DC power supply 112 is controlled by the computer control 105 .
- variable resistance load 104 is also used to mimic the behavior of a switch in the open circuit position by programming its resistance to over 10 mega-ohms
- the switch 108 there is only one initially charged battery 101 a
- a power supply has been added in series with the initially charged battery 101 a via the switch 108 to insure the battery 101 a voltage can be boosted to a higher potential than the initially discharged battery 103 during the entire energy transfer cycle, insuring all the energy from the initially charged battery 101 a will be transferred.
- This embodiment has the advantage of potentially transferring energy between the batteries more efficiently.
- the DC power supply 112 is bypassed by the switch 108 .
- the computer 102 determines the battery voltages are insufficient to properly transfer energy in the proper direction between the said batteries, the DC power supply 112 is utilized to force the energy transfer.
- At least one embodiment of our machine for reclaiming energy stored in rechargeable batteries for charging other batteries during the batteries manufacturing process provides a more energy efficient, faster throughput, and more reliable process than that currently in use.
Abstract
Description
- The following is a tabulation of some prior art that presently appears relevant:
-
US Patents Patent Number Kind Code Issue Date Patentee 0,169,785 A1 2008 Jul. 17 Bongyoung Kim, Yongin-si 6,518,726 B1 2003 Feb. 11 Ronald D. Nowlin, Jr. et al. 5,666,006 A 1997 Sep. 09 David B. Townsley et al. - Certain types of a battery, such as a large lithium polymer or a large lithium ion phosphate battery used in an electric automotive vehicle application, may have a manufacturing process which includes charging the battery and at a later time discharging the battery. This cycling may be done in part or in full more than one time. This charging, storage, and discharging the battery may be done to test the battery, to store energy, to release energy, to help in the forming of the battery, or for other reasons.
- Traditionally, charging the battery in its manufacturing process is accomplished using an electronic battery charger which converts power from the AC power mains to a DC form readily useable by the battery. The battery is traditionally charged alone or with one or more batteries in series, parallel, or in a series/parallel combination.
- Likewise, the battery discharge in its manufacturing process is typically accomplished by connecting the battery to a resistive load. The battery is traditionally discharged by itself or with one or more batteries in series, parallel, or in a series/parallel combination.
- Traditionally, the charging of one battery and the discharging of a different battery in the battery manufacturing process is performed independent of each other.
- Each time the discharged battery is charged using the electronic battery charger, the electronic battery charger typically converts power from the available AC mains into the DC form required by the battery. This AC power consumed incurs a cost to the manufacturing facility.
- Each time the battery is discharged into an active or passive resistive load, the energy stored in the battery is converted to heat. This heat is often unwanted in the manufacturing area and removed by the manufacturing facility's cooling systems. This additional cooling requirement incurs a cost to the manufacturing facility.
- Traditionally, a lithium polymer or lithium ion phosphate battery for automotive electric vehicle applications is charged and discharged along with other batteries in series and/or in parallel during the manufacturing process. A failure of a battery is often not detected until after the charging or discharging cycle is complete and the battery is connected to a test station. Where the failed battery had been charged in series with other batteries, the entire string of batteries being charged often needed to repeat the charging cycle again.
- In accordance with one embodiment: the energy for charging a lithium polymer or a lithium ion phosphate battery during the manufacturing process of said battery will be partly or fully provided by other batteries which are being discharged during their manufacturing process, the process of charging one battery and concurrently discharging one or more different batteries speeds-up testing through-put when compared to sequential manufacturing, energy from the AC mains that has been used to charge a battery may be partly recycled and used to charge one or more other batteries, the energy consumption from the AC mains to cool the manufacturing facility may be reduced, and each battery may be monitored during charging/discharging and replaced in real time if a problem is detected.
-
FIG. 1 is a circuit diagram of the first embodiment -
FIG. 2 is a system flowchart outlining an example machine using the first embodiment -
FIG. 3 is a circuit diagram of alternative embodiment -
FIG. 4 is a system flowchart outlining an example machine using the alternative embodiment -
-
- 101 a initially charged battery
- 101 a− negative terminal of initially charged battery
- 101 a+ positive terminal of initially charged battery
- 101 b initially charged battery
- 101 b− negative terminal of initially charged battery
- 101 b+ positive terminal of initially charged battery
- 102 computer
- 103 initially uncharged or discharged battery
- 103− negative terminal of initially uncharged or discharged battery
- 103+ positive terminal of initially uncharged or discharged battery
- 104 variable resistance load
- 105 computer control
- 106 ammeter, represented in
FIG. 1 by an encircled “A” - 107 computer inputs/outputs to measure and control circuit parameters
- 108 switch
- 109 a initially charged battery
- 109 b initially uncharged or discharged battery
- 110 scanner for recording battery serial numbers
- 111 robot for moving batteries
- 112 DC power supply
- One embodiment is illustrated in
FIG. 1 which shows the circuit diagram of a battery charging, discharging, and testing machine for use in battery manufacturing and which may be used specifically with the type of lithium ion phosphate batteries that power electric vehicles. In this example circuit, an initiallycharged battery 101 a, which has anegative terminal 101 a− and a positive terminal 101 a+, is on the bottom and an initiallycharged battery 101 b, which has anegative terminal 101 b− and a positive terminal 101 b+, is on the top of this series connected pair. The positive terminal of the top battery 101 b+ is connected through aswitch 108 to anammeter 106 which is represented inFIG. 1 by an encircled “A”, through avariable resistance load 104, and into a positive terminal 103+ of an initially discharged oruncharged battery 103. Anegative terminal 103− of this initially discharged oruncharged battery 103 is connected to thenegative terminal 101 a− of thecharged battery 101 a, completing the circuit. - The
switch 108 can be set to one of two possible positions by acomputer control 105. Alternatively to the aforementioned connection, theswitch 108 could be placed in an open configuration where it disconnects the initially chargedbattery 101 b from theammeter 106. - In addition to controlling the
switch 108, thecomputer control 105 also controls thevariable resistance load 104. A computer inputs/outputs 107 connects to and performs measurements (including voltage readings) on all battery terminals as well as theammeter 106. - An additional initially charged
battery 109 a and an additional initially discharged oruncharged battery 109 b are present but are not connected to the circuit. Abar code scanner 110 for identifying each battery is also attached to the computer inputs/outputs 107, and arobot 111 is connected to thecomputer control 105. Thecomputer control 105 and the computer inputs/outputs 107 are some of the interfaces to acomputer 102. - The machine in
FIG. 1 follows the machine flowchart ofFIG. 2 . Theswitch 108 is set to open circuit. The initially chargedbattery 101 a on the bottom and the initially chargedbattery 101 b at the top of the series batteries are installed along with the initially uncharged or dischargedbattery 103 into the machine's circuit via therobot 111 which concurrently uses thescanner 110 to read the serial numbers of the batteries as they are being installed. This serial number data enters the computer inputs/outputs 107 and is recorded in a file on thecomputer 102. In order to continue in their manufacture process,battery 103 must be charged andbatteries FIG. 1 as shown. The computer inputs/outputs 107 measures and/or performs tests on these three batteries individually. This data is recorded in the file with the respective battery's individual serial number. - The
computer 102 analyzes the collected data from the battery measurements and determines if the batteries are functioning properly. If not, the failed battery is removed by therobot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on thecomputer 102, and an appropriate replacement battery is loaded into the circuit. If the batteries are properly functioning, thecomputer 102 determines the appropriate resistance—based on measured battery voltages and an algorithm—and sets thevariable resistance load 104. It closes theswitch 108 and discharging of the initially chargedbatteries battery 103 begins. - The computer inputs/
outputs 107 continue to monitor the batteries and thecomputer 102 determines if they are properly functioning. If a problem is detected, theswitch 108 is opened and the failed battery is removed by therobot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on thecomputer 102, and an appropriate replacement battery is loaded into the circuit. - The
computer 102 next determines if either of the initially chargedbatteries switch 108 is opened. Thecomputer 102 next determines if the discharged battery delivered the required stored energy. If so, the battery passes, is removed by therobot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on thecomputer 102, and anappropriate replacement battery 109 a is loaded into the circuit. If the discharged battery did not deliver the required stored energy, the battery fails and is removed by therobot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on thecomputer 102, and anappropriate replacement battery 109 a is loaded into the circuit. - The
computer 102 next determines if the initially uncharged or dischargedbattery 103 is fully charged. If it is, theswitch 108 is opened. Thecomputer 102 next determines if the chargedbattery 103 received the required stored energy. If so, thebattery 103 passes, is removed by therobot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on thecomputer 102, and anappropriate replacement battery 109 b is loaded into the circuit. If the chargedbattery 103 did not receive the required stored energy, thebattery 103 fails and is removed by therobot 111 and placed in an appropriate pile, the results are recorded with the battery's serial number on thecomputer 102, and anappropriate replacement battery 109 b is loaded into the circuit. - As shown in the circuit diagram of
FIG. 3 , this alternative embodiment utilizes aDC power supply 112 whose positive output is connected to the previously open side of theswitch 108 and whose negative output is connected to the positive terminal 101 a+ of thebattery 101 a to be discharged. Additionally, theDC power supply 112 is controlled by thecomputer control 105. - The system in
FIG. 3 follows the flowchart ofFIG. 4 . It is very similar to the embodiment previously discussed except: (1) thevariable resistance load 104 is also used to mimic the behavior of a switch in the open circuit position by programming its resistance to over 10 mega-ohms, (2) there is only one initially chargedbattery 101 a, (3) a power supply has been added in series with the initially chargedbattery 101 a via theswitch 108 to insure thebattery 101 a voltage can be boosted to a higher potential than the initially dischargedbattery 103 during the entire energy transfer cycle, insuring all the energy from the initially chargedbattery 101 a will be transferred. - This embodiment has the advantage of potentially transferring energy between the batteries more efficiently. When the initially charged
battery 101 a is significantly higher in voltage than the initially uncharged or dischargedbattery 103, theDC power supply 112 is bypassed by theswitch 108. When thecomputer 102 determines the battery voltages are insufficient to properly transfer energy in the proper direction between the said batteries, theDC power supply 112 is utilized to force the energy transfer. - From the description above, a number of advantages of these embodiments become evident:
- (a) By discharging a group of charged batteries into a group of discharged batteries, part of the energy stored in the first group is transferred into the second group, thus eliminating the need and cost of converting energy from the AC mains for use in charging the discharged batteries.
- (b) By discharging a group of charged batteries into a group of discharged batteries, cooling costs for the manufacturing facility may be reduced as all of the energy stored in the second group of batteries would typically have been converted into heat during the battery discharge process of the first group.
- (c) The concurrent nature of discharging a group of charged batteries into a group of discharged batteries reduces the time which would be required for manufacturing equipment to discharge a group of charged batteries and then charge a group of discharged batteries sequentially.
- (d) By repeatedly testing each battery during its charging or discharging cycle, a battery failure can often be found prior to testing the batteries at the completion of the cycle, thus enabling the failed batteries in the string to be replaced and saving the time and energy which would be required to repeat the charging or discharging cycle for these other batteries in the circuit.
- (e) By serializing the batteries and automating their movement through this charging, storage, and discharging circuit through the use of the scanner, robot, and computer, human errors in sorting the batteries are reduced or eliminated and the process can be expedited.
- (f) The automation of the calculations by the computer in determining if the appropriate amount of energy was removed or stored into the battery will further reduce human errors in determining if each battery is properly functioning.
- (g) By expanding the number of batteries being discharged by adding more batteries in series or in parallel and by expanding the number of batteries being charged by adding more batteries in series or in parallel in
FIG. 1 , along with their associated interconnections and software, the volume of batteries which can concurrently be processed in a single machine can be increased. Obviously, the voltage on the batteries being discharged must always be higher than the voltage on the batteries being charged. - Thus the reader will see that at least one embodiment of our machine for reclaiming energy stored in rechargeable batteries for charging other batteries during the batteries manufacturing process provides a more energy efficient, faster throughput, and more reliable process than that currently in use.
- While my above descriptions contain many specificities, these should not be construed as limitations on the scope, but rather as an exemplification of some embodiments thereof. Many other variations are possible.
- Accordingly, the scope should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
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US13/672,483 US8933669B2 (en) | 2012-11-08 | 2012-11-08 | Reclaiming energy stored in rechargeable batteries for charging other batteries |
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Cited By (2)
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JP2017073343A (en) * | 2015-10-09 | 2017-04-13 | 株式会社デンソー | Charge/discharge control device and battery pack device |
CN112051508A (en) * | 2020-07-28 | 2020-12-08 | 国网江西省电力有限公司电力科学研究院 | Method for evaluating performance consistency of secondary utilization lead-acid storage battery |
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CN104901409B (en) * | 2015-06-30 | 2017-03-29 | 深圳市卓能新能源股份有限公司 | What a kind of battery pack low pressure charged realizes device |
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US5666006A (en) | 1994-05-12 | 1997-09-09 | Apple Computer, Inc. | Circuit offering sequential discharge and simultaneous charge for a multiple battery system and method for charging multiple batteries |
US6518726B1 (en) | 2002-01-18 | 2003-02-11 | Eagle-Picher Technologies, L.L.C. | Battery charger and charge control system |
EP1947729B1 (en) | 2007-01-17 | 2010-09-22 | Samsung SDI Co., Ltd. | Hybrid battery |
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JP2017073343A (en) * | 2015-10-09 | 2017-04-13 | 株式会社デンソー | Charge/discharge control device and battery pack device |
CN112051508A (en) * | 2020-07-28 | 2020-12-08 | 国网江西省电力有限公司电力科学研究院 | Method for evaluating performance consistency of secondary utilization lead-acid storage battery |
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